'99 Windstar EGR Insufficient Flow Detected
 

Hi all,
Have the check engine light on now. OBD device gave code of Insufficient Flow in EGR. A friend tells me that carbon builds up in ports located in the lower intake area. He says that you have to manually remove the carbon build up in six small ports,but I am hesitant to simply begin removal. I fear that the carbon pieces will end up in the engine beyond my reach. I have looked over a Haynes manual and no info is given on this repair. Worse yet, I have a Ford Technical Service Publication that doesn't describe this cleaning procedure. Any feedback would be a big help. Thanks in advance.

RE: '99 Windstar EGR Insufficient Flow Detected
 

3.0 or 3.8?

DPFE sensors fail at a fairly high rate and will set a insufficient flow code as well.. The DPFE monitors EGR flow rate/pressure.. Here's a pic of the DPFE..

[IMG]local://upfiles/6756/66FF5033D8364BF4A881F9A182387044.gif[/IMG]

RE: '99 Windstar EGR Insufficient Flow Detected
 

Hi,
Thanks for the info. I did replace this sensor but still have the same code coming up on OBD. Any other ideas would be appreciated. Thanks in advance.

RE: '99 Windstar EGR Insufficient Flow Detected
 

Oh yeah, By the way, the motor in this vehicle is the 3.8

RE: '99 Windstar EGR Insufficient Flow Detected
 

Try removing the EGR and making sure its clean as well as the port and the tube running back to the exhaust. You should only have to clean out one port on the intake side. The carbon will be a greasy and thick. Use a shop vac allong with a wooden dowel to remove what you can. Then use a carb cleaner to blast a few shot into the port and then work on the exhaust part. If that doesn't work and check the vacuum. Applying vaccum to the valve with the engine running should cause the motor to run rough/stumble at idle. You can apply vaccum simply by hooking it directly to the vaccum source on the manifold or suck on it with lung power. If it does notstumble with vacuum applied to the valve, then it should mean that the EGR is not working, granted all the ports/tubes are clear. If it does stubmle (valve is opening), check the vacuum line, it may be restricted. So basically if everything is clean, the senor is new, and you can't get the valve to open wtih manuel vaccum applied, then its time for a new valve.
Good Luck